RFID Unleashed

INSY 4700
Manufacturing Systems

RFID

Industrial and Systems Engineering

Outline
1. Definitions & Terminology
1. Definitions & Terminology

2. Technical Characteristics
2. Technical Characteristics

3. Common Applications
3. Common Applications

4. Efficiencies and ROI
4. Efficiencies and ROI

5. Future Trends
5. Future Trends

6. Concluding Remarks
6. Concluding Remarks

10/20/2005 Industrial and Systems Engineering

Definitions & Terminology
RFID stands for:
Radio Frequency IDentification

Radio Frequency IDentification (RFID) is
an automatic identification and data
capture (AIDC) method, relying on storing
and remotely retrieving data [1].


RFID System Components
- Transponders (tags) to physically carry the data
- Interrogators (readers) to retrieve the data
- Means and medium (air interface) to communicate the data
- Host computer
- Information management system (Middleware)


A tag is an electronic transponder that is used
to store and relay the data.
The word transponder means:
TRANSmitter/resPONDER
First invented as IFF (identification friend or
foe) in 1939 by British in order to positively
identify unknown airplanes detected by radar.
And then used again as an espionage tool
(covert listening device) invented by Leon
Theremin for Russian Government in 1945 [1].



TAGS

SEMI
ACTIVE PASSIVE ACTIVE


Active Tag
A battery-powered data carrying device
that reacts to a specific, reader produced,
inductively coupled or radiated
electromagnetic field, by delivering a data
modulated radio frequency response. The
battery is used to boost the reading range
[2].


Passive Tag
A battery-free data carrying device that reacts to
a specific, reader produced, inductively coupled
or radiated electromagnetic field, by delivering a
data modulated radio frequency response.
Having no internal power source, passive
transponders derive the power they require to
respond from the reader/interrogator's
electromagnetic field [2].


Semi-Active (Semi-Passive) Tag
A battery activated transponder where
battery is used to power the sensor and/or
the volatile memory of the tag. The
battery is not used to boost the reading
range [2].


Reader/interrogator is an electronic
device for performing the process of
retrieving data from a transponder and, as
appropriate, the contention and error
control management, and channel and
source decoding required to recover and
communicate the data entered at source [2].



Air interface is the conductor-free
medium, usually air, between a
transponder and the reader/interrogator
through which data communication is
achieved by means of a modulated
inductive or propagated electromagnetic
field [2].


RS232
A common physical interface standard specified by the Electronic
Industries Association (EIA) for the interconnection of devices. The
standard allows for a single device to be connected (point-to-point)
at baud values up to 9600 bps, at distances up to 15 meters. More
recent implementations of the standard may allow higher baud
values and greater distances [2].

RS422
A balanced interface standard similar to RS232, but using
differential voltages across twisted pair cables. Exhibits greater
noise immunity than RS232 and can be used to connect single or
multiple devices to a master unit, at distances up to 3000 meters [2].

RS485
An enhanced version of RS422, which permits multiple devices
(typically 32) to be attached to a two wire bus at distances of over
one kilometer [2].


Backscatter Modulation
A process whereby a transponder
responds to a reader/interrogation signal
or field by modulating and re-radiating or
transmitting the response signal at the
same carrier frequency [2].


Capacity - Data A measure of the data, expressed in
bits or bytes, that can be stored in a transponder. The
measure may relate simply to the bits that are accessible
to the user or to the total assembly of bits, including data
identifier and error control bits [2].

Capacity - Channel A measure of the transmission
capability of a communication channel expressed in bits
and related to channel bandwidth and signal to noise
ratio by the Shannon equation;
Capacity, C = B log2 (1 + S/N), where B is the bandwidth
and S/N the signal to noise ratio [2].


Carrier Frequency
The frequency used to carry data by
appropriate modulation of the carrier
waveform, typically in a radio frequency
identification system, by amplitude shift
keying (ASK), frequency shift keying
(FSK), phase shift keying (PSK) or
associated variants [2].


Contention (Clash)
Term denoting simultaneous transponder
responses capable of causing potential
confusion, and misreading, within a
reader/interrogator system unequipped
with anti-contention facilities [2].



Electromagnetic Spectrum
The range or continuum of electromagnetic radiation,
characterized in terms of frequency or wavelength [2].

Electromagnetic Wave
A sinusoidal wave in which electric E and magnetic H
components or vectors can be distinguished at right
angles to one another, and propagating in a direction
that is at right angles to both the E and H vectors. The
energy contained within the wave also propagates in the
direction at right angles to the E and H vectors. The
power delivered in the wave is the vector product of E
and H (Pointing Vector) [2].


Technical Characteristics
RFID System Categories
1. EAS systems
2. Portable data capture systems
3. Networked systems
4. Positioning systems


Passive tags need energy to power them, this energy is realized
from the reader’s transmit field. Power density is not influenced
by frequency, however, received power is dependent on
antenna size which in turn is dependent on frequency. The
amount of energy collected is a function of the aperture of the
receiving antenna, which in simple terms is related to the
wavelength of the received signal.


The data is communicated back to the
reader by changing one of the parameters
of the carrier signal listed below:
– Frequency
– Amplitude
– Phase


Non-contact and non-line-of-sight
communication is the unique objective of
RFID systems. The process, where the
data is transferred from the tag to the
reader, is called modulation. During
modulation data is superimposed on the
carrier wave by the following techniques:
– FSK
– ASK
– PSK


Frequency Ranges


Attractive Frequencies

125 kHz (LF)
Near field
13.56 MHz (HF)

430-926 (400-1000) MHz (UHF)
2.45 GHz (Microwave) Far field



PROBLEM

Frequency allocation inconsistency
across the world!
SOLUTION

Countries are required to achieve some
uniformity by 2010.

RF Module is the heart of RFID System

– Proximity (100mm.)

– Medium range (400mm.)

– Vicinity (1.5m.)


Reading range depends upon:

1. Power available at the reader/interrogator
2. Power available within the tag
3. Propagation/environmental circumstances
(especially at high frequencies)
4. Structures/cross-sections/obstructions


Active Tags Passive Tags
Greater size Less cost
Greater cost Lighter weight
Greater range Unlimited lifetime
Shorter range
Limited data capacity



SIGNAL STRENGTH IS
INVERSELY PROPORTIONAL TO
THE SQUARE OF THE DISTANCE


Phenomena impacting propagation:
1. Reflection (conductive surfaces, i.e. metal)
2. Multi-path attenuation
3. Absorption due to moisture (air interface)
4. Penetration (liquids)
5. Refraction (conductive medium change)
6. Interference (noise)
7. Distortion
8. Difraction (sharp edges, corners, etc.)


DATA HANDLING

versus
PML??

01.00058A.00198.00120389


Data Organization (Source Encoding)
Identifiers (128 to 512 bits) :
1. Numeric/alphanumeric string for
identification purposes (UPC and/or EPC)
2. Access key to data stored elsewhere
(remote database and/or database
repository)
Portable Data Files (64Kb)



DATA PROGRAMMING OPTIONS
• Read-only
• WORM
• Read/Write


Reader/Interrogator Command Response Protocol
“Contention/Clash/Collision Management”

Hands Down Polling:
Reading multiple tags during a short time interval
Hands Up Polling:
Looking for tags with specific identities and interrogating
them in sequence
Further Approach:
Using multiple readers and multiplexing them into one
interrogator.



Tag talks first:
Works very well with longer read ranges to capture and
record fast moving objects such as motor vehicles,
cyclists, sporting event competitors, objects moving
along conveyor belts, (baggage, parcels etc) There are a
number of collision avoidance schemes which enhance
the use of Tag Talks First
Reader talks first:
Useful where there is a large volume of items where
collision avoidance is required and unique identification
of individual tags is needed. This system is most useful
when tags are stationary or very slow moving.



UPC (Universal Product Code)
The 12-digit EAN.UCC System
data structure composed of a
UCC Company Prefix, Item
Reference, and Check Digit. It
is used to identify trade items,
and special applications (e.g.,
coupons) [3].
BATCH (SKU) LEVEL
(SKU: Stock Keeping Unit)


The Electronic Product Code™ (EPC) is the next
generation of product identification. The EPC is
a simple, compact “license plate” that uniquely
identifies objects (items, cases, pallets,
locations, etc.) in the supply chain.
The Electronic Product Code (EPC) is a number
designed to uniquely identify every single
instance or a product, e.g. every jar of coffee
produced will have its own unique identity.


An EPC number contains:
1. Header, which identifies the length, type, structure, version
and generation of EPC
2. Manager Number, which identifies the company or company
entity
3. Object Class, similar to a stock keeping unit or SKU
4. Serial Number, which is the specific instance of the Object
Class being tagged [4].

ITEM LEVEL

01.00058A.00198.00120389


The Object Name Service (ONS) is very
similar to the Domain Name Service
(DNS) of the Internet. The ONS service
translates EPC numbers into Internet
addresses. It enables information queries
based on EPC numbers to be routed to
the databases that contain the required
information [4].


MANUFACTURING

TECHNIQUES
• SURFACE MOUNT TECHNOLOGY
(10,000 tags/hr.)
• FLUIDIC SELF ASSEMBLY
(2,000,000 tags/hr.)
Nanoblock technology

10 to 300 Billion tags by 2010
$0.30/tag now
$0.05/tag by 2010


HUMAN SAFETY

World-wide standards:
+ANSI C95.1 SAR=1.6W/kg
Head & Trunk
+ICNIRP SAR=2W/kg

+ANSI C95.1 SAR=3.2W/kg
+ICNIRP SAR=4W/kg
Limbs

125kHz & 13.56MHz are OK
UHF and Microwave suffer severe limitations!


Common Applications
DoD Mandate
The US Department of Defense has issued a series of
RFID policy guidelines that state the requirements for its
suppliers to meet.
Passive RFID tags are required for all DoD contracts
issued on or after Oct 1, 2004, for delivery of materials
on or after Jan 1, 2005. Passive tags need to be applied
to all freight/cargo containers, cases, pallets and to
individual quot;high-valuequot; items that require the military's
UID (Unique Identification Code). Containers shipped
outside the continental US need to have active tags with
content and point of origin information.


Common Applications
WalMart Mandate
WalMart has directed that its top 100 suppliers
use RFID tagging by Jan 1, 2005. Passive RFID
tags will be required on pallets and cases,
identified with an EPCglobal symbol. However,
due to technical difficulties, the plan has been
scaled back a bit since then.
Since Wal-Mart first announced their RFID
policy, other companies, including Target,
Albertsons, Best Buy Co, Circuit City and Kroger
have either officially announced plans or are in
the process of doing so.

Common Applications
EAS (Electronic Article Surveillance)
Deterrence against theft/pilferage
Prevention of fraud/counterfeiting
Item tracking/security


Common Applications
Manufacturing
Tool carriers
Monorail/Power/Free conveyors/trolleys
Lift trucks
Towline carts
AGV’s
Valuable assets (cars, electronics)
Refurbishing/reengineering


Common Applications
Shipping/Receiving/Distribution
Warehouse management
Pallet, tote, box, container, barrel, tub,
parcel, package identification
Cross-docking operations
Carton making
Advance shipping label
Return/recall/repair management
Hazardous material handling

Common Applications
Biometrics/counter-terrorism
Vehicle/staff access control
Container security (light and vibration sensitive tags,
SST, RFID cargo seals)
NEXUS secure border crossing between US and
Canada
Military (Common Access Card)
Photo ID Cards


Common Applications
Transportation
Railcar tracking
Toll collection
Commercial truck monitoring
Automobile tracking


Common Applications
Healthcare services
Patient safety and flow monitoring
Critical equipment tracking
Drug/blood locating
Drug/blood safety
Newborn services


Common Applications
Cold chain management
Animal tagging and husbandry
Airline baggage safety
Express parcel delivery


Common Applications
Leaders


Efficiencies and Return on Investment

RFID system costs breakdown:
25% Reader systems
50% Software and integration
15% Initial tagging
10% Operating expenses and installation



Sample cost scheme for a retailer:
Labor costs = 90% of Distribution center costs
Receiving costs =30% of labor costs
Manual receiving operations = 60% of receiving
And…
10% labor cost increase per year !!!
2% Sales write-off due to theft/pilferage !!!



For closed loop applications (valuable
asset tracking, RTLS, etc.) ROI is
quantifiable.

For trading partner networks although net
figures are not available yet…..


What’s good in it?
– Leaner manufacturing due to less waste
– Better inventory management (less obsolescence
higher inventory turnover ratio)
– Increased visibility
– Enhanced asset utilization
– More deterrence against theft/pilferage
– More data (more information???)
– Better quality control & customer service
– Container loss prevention within trading partnerships
– Reduction of new asset purchase
– Asset shrinkage reduction


New Trends

Electromagnetic phenomena like reflection,
penetration, etc. limits the usage of RFID
systems with liquids and metals.

Hence a new technology called Surface Acoustic
Wave (SAW) is being used.


New Trends
SAW RFID Operation:

The reader emits a radio wave pulse that is directly
converted into a nanoscale Surface Acoustic Wave on
the SAW chip surface by the quot;IDTquot; (interdigital
transducer). That acoustic wave travels past a set of
wave reflectors to produce uniquely encoded acoustic
wave pulses, which travel back to the IDT. The IDT
converts those pulses into an encoded radio wave reply
signal that is sent back to the reader. The SAW chip
operates using the piezoelectric effect and does not
require DC power. (Note: chip size is not to scale.) [5]


Concluding Remarks
RFID is not:
– Panacea or silver bullet
– The flavor of the month
– For all kinds of businesses
– A tool for identification of “everything” on
Planet Earth


Concluding Remarks

RFID is a highly technological solution to business
problems.

RFID is the enabling technology for today’s businesses
provided that intelligent diffusion is deployed.

The main criteria for adopting and implementing RFID
systems are:
– Fit for purpose
– Existence of line-of-sight access problems


Concluding Remarks


References
[1] http://en.wikipedia.org/wiki/RFID
[2] http://www.aimglobal.org
[3] http://www.gs1us.org/gs1us.html
[4] http://www.epcglobalinc.org
[5] http://www.rfsaw.com
Photos and clipart are from various
sources form the world wide web.


RFID Unleashed

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